JP6985485B2 - A method for manufacturing an airtightly sealed LED lamp and an airtightly sealed LED lamp. - Google Patents

Description

The present invention relates to an airtightly sealed LED lamp and a method for manufacturing the airtightly sealed LED lamp. The invention more specifically relates to LED lamps used in the medical field, i.e., for medical devices and appliances.

LED lights are becoming more and more popular in the medical field, especially in dentistry equipment, and it can be safely said that they are even part of medical equipment. LED lamps are used for lighting purposes, for example to illuminate the patient's oral cavity, and also emit light of a specific wavelength that facilitates identification of defective sites, for example, especially as a camera light for an endoscope. It is used to detect defective parts such as worm teeth, and is also used to cure fillers, for example to cure curable plastics using UV light.

Such LED lights are typically exposed to high loads. In particular, most medical devices need to be airtightly sealed and, in some cases, even autoclaveable.

Furthermore, the equipment used should be durable and should not release any harmful substances.

In particular, from dental instruments, handles including LED light sources are known. The LED light source is most often built into the housing of the handle, and the light emitted by the LED light source is directed to a window in the tip area of the handle using a light guide, through which the light enters the oral cavity. Incident to.

Known LED lamps, for example sealed with a polymeric potting compound, are usually not well suited for use with medical devices, at least outside.

Accordingly, the present invention provides an airtightly sealed LED lamp that is well suited for incorporation into medical devices and is capable of meeting increasing demands in the medical field in terms of durability and airtightness. It is based on the task of doing.

The subject of the present invention is already solved by the airtightly sealed LED lamp described in the independent claim and the method for manufacturing the airtightly sealed LED lamp.

Preferred embodiments and improvements of the invention are defined by the subject matter of each dependent claim.

The present invention relates to an airtightly sealed LED lamp, which is an LED lamp having at least a liquidtight housing.

LED lights include bases with multiple LEDs.

Preferably, these LEDs are mounted in the form of LED chips directly coupled to the base.

Such LED chips can include high power LEDs, heat is easily dissipated through the base, and the components are compact.

The base is made of ceramic material. In particular, the base is made of aluminum oxide and / or aluminum nitride.

LED lights also include a metal cap with at least one window. The metal cap preferably has a plurality of windows, each of which faces an LED, through which light is emitted from the LED lamp.

The metal cap is soldered to the base, and the LED lamp further extends through both the base and cap to guide electrical, optical, and / or mechanical elements. Has.

A unit in the form of an LED lamp that achieves high density by soldering a ceramic base to a metal cap, despite the existence of channels that extend through these components. It became possible to provide.

Channels are used specifically to accommodate electrical or mechanical elements that are part of the adopted medical device.

For example, an image sensor and a camera in particular can be arranged in the channel, and an LED lamp is used as a light source for these.

The channel can have any shape, especially conical, cylindrical, or polygonal. For example, it is conceivable to provide a stepped channel by making the diameter of the channel different between the base and the cap. In this case, such a staircase can be used as a stopper to better hold the mechanical or electrical element.

In one preferred embodiment, the LED lamp has a ring shape and the channels are located approximately in the center.

The LEDs are preferably distributed around the ring thus formed. The LED lamp can include, in particular, 4 to 10 LEDs.

Such LED lights can be placed specifically on the headpieces of medical devices, such as dentist drilling devices. In this case, the drill and / or the drive shaft of the drill device itself can extend through the channel and these LEDs are used specifically for lighting purposes.

Preferably, the LED comprises a plurality of windows distributed in a ring shape.

In one improved form of the invention, the window is defined by a lens.

In particular, the LED light can be focused through the window.

In one preferred embodiment, each of the plurality of windows is located within each channel of the metal cap. The channel in which the windows are arranged preferably has a height of 0.15 to 20 mm. Preferably, each channel extends to its own base, i.e., a metal cap is soldered to the base directly adjacent to each channel.

In particular, it is conceivable that the metal cap will have channels, preferably cylindrical, particularly cylindrical in shape, into which a glass window in the form of a lens will be welded.

In order to manufacture such a metal cap, a portion of the glass rod can be introduced into the channel. When the glass is heated, it melts and the surface tension of the glass forms a lens.

In one embodiment, the LED light comprises a plurality of windows and the metal cap has a recess adjacent to each window.

In particular, the metal cap has a recess on the top surface adjacent to the channel.

If a glass window is welded into the channel to form the lens, the lens will not protrude from the top of the metal cap due to the indentation, so this LED light will not use a separate protective glass. The window will not be damaged when it comes in contact with an object. Because the metal cap is adjacent to the window.

In one embodiment of the invention, the transducer is located in the channel under the window. In particular, a transducer having a silicone carrier matrix in which fluorescent particles such as phosphorus and YAG are embedded can be used. The transducer can be particularly easily mounted within the channel, for example by bonding with an adhesive. The use of silicone matrix transducers results in ease of manufacture and improved temperature stability. The use of transducers with an inorganic matrix can be considered as well.

An LED with a wide beam angle or emission angle, preferably by welding a glass window into the channel and preferably placing this glass window as close as possible in front of an optionally adopted transducer. It will be possible to provide lights.

In particular, the emission angle can be greater than 85 °, preferably greater than 90 °, more preferably greater than 94 °. In the context of the present invention, the exit angle represents the angle contained between the horizontal points of the half width of intensity.

The present invention further relates to airtightly sealed LED lamps, in particular LED lamps as described above.

Such LED lamps include a base with a plurality of LEDs and at least one cap having a plurality of windows, preferably a ceramic base, and the LED lamps have different light colors that can be controlled separately. The light emission angles of at least two separately controllable LEDs, including the plurality of LEDs of the above, are different from each other.

Accordingly, an LED lamp comprises a plurality of LEDs of different light colors for a plurality of different uses. When LED lights are provided for the dental field, these LEDs are, for example, LEDs with near-white light for illuminating the oral cavity and special lights for detecting tooth decay and scoliosis. Colored LEDs and LEDs that emit UV light used to cure the resin can be included. These LEDs can be controlled separately. For this purpose, the base has multiple electrical feedthroughs for each LED or for each set of LEDs.

In particular, it is conceivable to have at least one LED have an emission angle less than 60 ° and another LED to have an emission angle greater than 70 °. Furthermore, it is particularly conceivable that the emission angles of at least two LEDs differ from each other by at least 10 °, preferably at least 20 °.

A plurality of windows are preferably used for this purpose, each of which is defined by a lens having a different focal length and / or a different aperture angle.

If these lenses are formed by melting glass into a channel, such lenses can be provided, for example, with channels of different shapes and / or different glasses.

For example, in the case of an LED that emits UV light, it is convenient to focus the light and radiation at a small emission angle, while the LED for illuminating the oral cavity has a wider emission angle.

The LED lamp is particularly a part of the medical device, and the LED lamp is incorporated in the medical device so that the light of the LED is directly emitted to the outside. That is, the light is not guided to exit the window through the light guide. However, it is also conceivable to provide another window or protective glass in the radial direction. However, preferably, the end of the medical device is defined by a metal cap with a window of the LED light.

The present invention further relates to a method for manufacturing an LED lamp, particularly a method for manufacturing an LED lamp as described above.

First, the LEDs arranged on the chip are assembled on the base made of ceramic. Then, the metal cap is soldered to the base using metal solder.

Preferably, the metal cap is provided with at least one window by melting or welding the glass into each channel of the metal cap already prior to the soldering step.

It is also conceivable to provide at least one window in the form of a compression glass-to-metal seal.

Glass windows are preferably made of materials with good chemical resistance, especially silicate glass, such as borosilicate glass.

After that, the only thing left to do is the connection of each component, that is, the metal cap with the window and the ceramic base.

Stable air sealing without the temperature of the LED lamps being high enough to pose a risk of damage to the LEDs in the form of LED chips, especially when appropriate solder is used, especially when gold tin solder is used. It has been found that a disconnected connection can be achieved.

By using gold-tin solder, it becomes possible to provide a housing that can be autoclaved.

Furthermore, this connection is stable during any subsequent soldering process, especially during the reflow process, or when tin-silver-copper solder is used.

Preferably, solder having a melting temperature of less than 300 ° C., more preferably less than 280 ° C., particularly gold-tin solder is used.

More preferably, the ceramic base has an electrical feedthrough that is hermetically sealed with metal solder.

These feedthroughs that are passed through to electrically connect the LEDs are also preferably formed prior to soldering the base and metal cap.

According to one improved embodiment of the invention, at least one metal cap is provided with a coating, particularly a coating containing nickel and / or gold. In particular, a hard gold coating is applied.

The metal cap is preferably made of stainless steel, especially stainless steel with a particularly low coefficient of thermal expansion. Therefore, the metal cap is adapted to the low coefficient of thermal expansion of ceramics. In particular, the material of the metal cap has a coefficient of thermal expansion α of less than 15 ppm / K, preferably less than 8 ppm / K, more preferably less than 5 ppm / K at room temperature.

In particular, the metal cap is made of ferritic stainless steel.

In one embodiment of the present invention, the difference between the coefficient of thermal expansion α of the metal cap and the coefficient of thermal expansion α of the window material is less than 5 ppm / K, preferably less than 1 ppm / K. The same is preferably true for the coefficient of thermal expansion of the base and the coefficient of thermal expansion of the metal cap.

Solder that can be used for feed-through for electrically connecting LEDs includes, for example, gold-tin solder, tin solder, copper solder, and silver solder.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide an airtightly sealed LED lamp that can even be autoclaved.

Hereinafter, the subject matter of the present invention will be described with reference to exemplary embodiments.

FIG. 3 is a plan view of an exemplary embodiment of an airtightly sealed LED lamp. It is sectional drawing of FIG. It is a figure explaining the detail of FIG. It is a bottom view. It is a schematic diagram explaining the use example of the airtightly sealed LED lamp which concerns on this invention in combination with an image sensor. It is a schematic diagram of the medical device which incorporated the airtightly sealed LED lamp which concerns on this invention. It is a figure which shows another exemplary embodiment of the airtightly sealed non-ring-shaped LED lamp.

FIG. 1 shows a plan view of an exemplary embodiment of the airtightly sealed LED lamp 1 according to the present invention.

In this embodiment, the LED lamp 1 has a ring shape. A metal cap 2 can be seen at the top, which has a plurality of windows 3 that allow light emitted from the underlying LED to pass through.

The LED lamp 1 can be connected via the feeder line 4.

The six windows 3 illustrated in this exemplary embodiment are distributed around the LED lamp 1.

Furthermore, a central channel 5 with a circular cross section is visible, which central channel 5 is intended to accommodate electrical, optical, or mechanical elements.

FIG. 2 is a cross-sectional view of the LED lamp illustrated in FIG.

It can be seen that the metal cap 2 made of stainless steel has a cup shape.

The base 6 made of a ceramic material, particularly aluminum oxide, is attached to the cup-shaped metal cap 2 from below, and is soldered to the metal cap 2 using gold-tin solder.

The plate-shaped base 6 is also ring-shaped, so that the channel 5 extends through both the base 6 and the metal cap 2.

The base 6 has a feedthrough (not shown), and the current for driving the LED is supplied to the upper surface through the feedthrough through the feeder line 4.

FIG. 3 illustrates the details of FIG. 2, i.e., the area where the window 3 is located.

Under the window 3, it can be seen that the base 6 is equipped with the LED 10. The LED 10 is mounted in the form of a chip, especially as a surface mount device (SMD).

On the upper surface of the base 6, for example, a feeder line in the form of a flat conductive trace (not shown) for electrically connecting the LED 10 can be provided.

Furthermore, it can be seen that the window 3 is provided in the form of a lens.

The window 3 is arranged in the channel 7, and the channel 7 itself extends through the metal cap 2.

The lenticular shape of the window 3 is due to the surface tension of the glass and is manufactured by inserting the glass rod into the channel 7 and then melting it.

A peripheral recess 8 is provided at the upper end of the channel 7.

Thanks to the recess 8, the window 3 in the form of a lens does not protrude.

Optionally, the transducer 9 may be arranged in the channel 7 according to the desired color of light. Such a transducer 9 can be, in particular, a transducer having a silicone matrix bonded by an adhesive in the channel 7.

Further, it can be seen that the upper surface of the base 6 is soldered to the lower surface of the cup-shaped metal cap 2.

In this embodiment, the edge of the base 6 is separated from the metal cap 2.

By connecting the base 6 and the metal cap 2 by soldering and melting the window 3 in the channel 7, airtight sealing of the LED 10 is realized.

The feedthrough in the base 6 is preferably filled with solder as well.

In order to assemble the LED lamp according to the present invention, first, a metal cap 2 to which a window is welded is manufactured, and separately, the LED 10 is attached to the base 6.

These two major elements are then soldered together using gold tin solder having a melting temperature of less than 340 ° C, preferably less than 325 ° C, more preferably less than 300 ° C.

The method of the present invention is suitable not only for the illustrated ring-shaped LED lamps, but also for other types of LED lamps, especially LED lamps that do not have a central channel.

FIG. 4 shows a bottom view of the LED lamp 1.

In this exemplary embodiment, a ring-shaped base 6 having feedthroughs 11 and 12 is visible, through which feedthroughs 11 and 12 drive an LED on the top surface.

The base 6 is fitted in a cup-shaped metal cap 2.

Further, a central channel 5 can be seen, and an electrical element, an optical element, or a mechanical element can be arranged in the central channel 5.

The feeder line 4 is in contact with the bottom surface and extends around the channel 5.

If one LED light has multiple LEDs that are controlled separately, this LED light will typically have two for a positive terminal and a negative terminal as shown in FIG. It should be understood that you can have more feedthroughs than feedthroughs. This is because each drive circuit for driving these LEDs is preferably placed externally rather than inside the airtightly sealed portion of the illustrated LED lamp.

FIG. 5 schematically shows an airtightly sealed LED lamp 1. The LED lamp 1 also includes a ring-shaped ceramic base 6 in this embodiment, to which a similarly ring-shaped metal cap 2 is soldered, and the metal caps 2 have a plurality of rings. It has windows 3, and light from the LED 10 is emitted to the outside through these windows 3.

An image sensor 13 and a lens 14 are arranged in the central channel 5.

FIG. 6 is a schematic diagram of a headpiece of a medical device, particularly a dental drill device.

The receptacle 16 can be seen, and a drill is inserted into the receptacle 16 so as to be connectable to the drive shaft.

The airtightly sealed LED lamp according to the present invention is directly attached to the head of the medical device 15, and the light from the LED lamp is directly emitted to the outside through the window 3.

Since the housing of the LED lamp according to the present invention is well sealed, it is not necessary to place the LED lamp in the housing of the medical device, and the emitted light is guided to the front by using a light guide. There is no need.

FIG. 7 shows one embodiment of an airtightly sealed LED lamp. Although this LED lamp does not have a ring-shaped structure, it is manufactured based on the method according to the present invention.

The LED lamp 17 includes a base 18 made of a ceramic material, particularly aluminum oxide, and a metal cap 19 made of stainless steel is soldered to the base 18 using gold-tin solder.

The base 18 is not disposed inside the metal cap 19, but is attached to the end face of the metal cap 19.

The metal cap 19 has a beveled edge. The solder 23 in the resulting gaps better bonds the elements together.

An LED 22 configured as a chip is arranged inside the airtightly sealed LED lamp 17, and the light from the LED 22 first enters the converter 21 placed on the LED 22. The transducer 21 is arranged under the window 20 in the form of a lens.

In order to manufacture the LED lamp 17, the window 20 is manufactured from the glass by first melting the glass in the metal cap 19. Optionally, the transducer 21 is additionally assembled in the metal cap 19.

Then, the metal cap 19 is soldered to the base 18 including the LED 22 already assembled.

1 LED light 2 Metal cap 3 Window 4 Feed line 5 channel 6 Base 7 channel 8 Indentation 9 Converter 10 LED
11 Feedthrough 12 Feedthrough 13 Image sensor 14 Lens 15 Medical device 16 Receptacle 17 LED light 18 Base 19 Metal cap 20 Window 21 Converter 22 LED
23 Solder

Claims (14)

It is an airtightly sealed LED lamp.
Includes a ceramic base on which at least one LED is mounted and at least one metal cap having multiple windows and soldered to the base.
The LED lamp has a channel extending through the base and the metal cap for introducing an electrical element, an optical element, or a mechanical element.
The difference between the thermal expansion coefficient α of the material of the thermal expansion coefficient α and the window of the metal cap state, and are less than 5 × 10 -6 ^{/ K,}
The plurality of windows are defined by lenses having different focal lengths and / or different aperture angles.
Airtightly sealed LED lamp. The difference between the coefficient of thermal expansion α of the metal cap and the coefficient of thermal expansion α of the material of the window is less than ^{1 × 10 −6 / K.}
The airtightly sealed LED lamp according to claim 1. The LED lamp has a ring shape with a centrally located channel.
The airtightly sealed LED lamp according to claim 1 or 2. Wherein the plurality of windows are distributed in annular,
The airtightly sealed LED lamp according to claim 3. Respective front Symbol plurality of windows, are arranged in respective channels provided in the metal cap,
The airtightly sealed LED lamp according to any one of claims 1 to 4. Before Symbol metal cap has a recess adjacent each window,
The airtightly sealed LED lamp according to any one of claims 1 to 5. A transducer is located in the channel under the window.
The airtightly sealed LED lamp according to claim 5 or 6. It ’s a medical device,
The airtightly sealed LED lamp according to any one of claims 1 to 7 is included.
The LED lamp is embedded in the medical device so that the LED light is directly emitted to the outside.
Medical equipment. The method for manufacturing an airtightly sealed LED lamp according to any one of claims 1 to 7.
First, assemble at least one LED on a ceramic base,
After that, the metal cap is soldered to the base using metal solder, and the metal cap is soldered to the base.
The difference between the coefficient of thermal expansion α of the metal cap and the coefficient of thermal expansion α of the material of the window is less than ^{5 × 10 -6 / K.}
A method for manufacturing an airtightly sealed LED lamp. The difference between the coefficient of thermal expansion α of the metal cap and the coefficient of thermal expansion α of the material of the window is less than ^{1 × 10 −6 / K.}
The method for manufacturing an airtightly sealed LED lamp according to claim 9. Gold tin solder is used to solder the metal cap to the base.
The method for manufacturing an airtightly sealed LED lamp according to claim 9 or 10. A window is provided in the metal cap prior to soldering the metal cap to the base.
The method for manufacturing an airtightly sealed LED lamp according to any one of claims 9 to 11. The window is manufactured by melting glass in each channel of the metal cap.
The method for manufacturing an airtightly sealed LED lamp according to claim 12. It said metal cap is coated with a coating containing nickel and / or gold,
The method for manufacturing an airtightly sealed LED lamp according to any one of claims 9 to 13.

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